Devices and control systems for inhaled drugs

ABSTRACT

Inhaled medications present a great opportunity for controlled drug delivery for self medicated patients. With this invention most medicinal aerosol generators have the potential for much more controlled dosage and monitoring of doses to the patient than current inhaled medication systems. The pressurized metered dose inhaler has especially great potential for controlled drug delivery being that the aerosol drug formulation is in a permanently sealed container that can use a digital program controlled electromechanical valve on a metered dose inhaler to control drug dose and time of release. An electromechanical inhaler valve actuator can also provide dose control, monitoring, breath activation timing and other important features.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under U.S. Application No. 62/454,843 filed Feb. 5, 2017

FIELD OF THE INVENTION

The present invention relates to methods and apparatus for electronically controlled drug inhaler devices. Specific embodiments may include but are not limited to more accurate inhaled doses, improved lung deposition of biologically-active substances, inhaler device easier to use, storage of data from producer, data from user and health care provider, program compensation for age, usage and environmental conditions to improve performance. Specific embodiments also include improvements to the medical pressurized metered dose inhaler using standard valves or improved valves.

BACKGROUND OF THE INVENTION

The typical pressurized metered dose inhaler (MDI) for delivery of aerosol drugs has many shortcomings for dose reproducibility and aerosol size distribution. Furthermore, many mechanical features of the pressurized metered dose inhaler such as orifice size and metering volume are fixed for an approved MDI. Although the combination drug/device product MDI has fixed aerosol drug formulation and fixed valve/actuator specifications the patient and environment can have significant variability changing inhaled drug treatment efficacy. For example, patients can have different disease conditions, treatment complications, age, weight, and different MDI use variables such as breath timing and actuation speed, force, etc. The MDI has many variables such as storage time, storage conditions, and pressure/temperature at the time of use effecting dose and aerosol size.

Software and/or firmware programs to control an electronically controllable MDI valve could reduce or eliminate many shortcomings of a totally mechanical MDI such as dose variation with storage or use temperature. Variations in drug aerosol size distribution and dose can change inhaled drug mass distribution in the lungs. This can be partly or totally compensated with software or firmware with a processor that can control an electromechanical MDI valve or valve actuator using data such as temperature, fluid pressure, fluid flow, doses used, time since last aerosol discharge, production date, shaking, etc. This invention with microprocessor controlled inhaler can also easily display data such as but not limited to doses used, doses remaining, expiration date or time to expiration date, programmed dose for delivery, warnings like too hot, too cold, needs shaking, needs priming dose, almost out of doses, inhaler battery low, inhaler needs to be replaced, and the like. The mechanical metered volume in the typical MDI also has variable pressure as the dose is released from the small fixed volume with changing flow and aerosol size during discharge. In this invention a partial volume discharge actuator or directly mounted electromechanical valve can reduce or eliminate this potential problem when it is controlled by a controller with the correct data inputs. Many of the non-adjustable mechanical variables in the typical MDI can be at least partly compensated for in a program and processor controlled MDI using an electromechanical valve or valve actuator. This present invention also discloses the optional heating device for a metered dose inhaler to improve aerosol formation and/or compensate for low temperature operating conditions of the MDI. This patent is different from U.S. Pat. No. 9,010,329 B2 filed Feb. 10, 2010 with one or more of the following condition sensors such as temperature, and/or pressure, flow, breath detection/activation combined with program control for valve control of the pressurized metered dose inhaler. This new patent also describes the use of a standard mechanical MDI valve and canister fitted with an electromechanical valve actuator that can be microprocessor controlled for the additional advantage of using mechanical valves that have a history of FDA or other approval(s) in other inhaler devices. The list below shows many of the advantages of a program controlled MDI with some potential applications to dry powder inhalers and nebulizers for delivery of drugs to the respiratory system. In the case of a dry powder inhaler the inhaler device program could control a powder container opener and/or electromechanical powder dispersion device. An inhaler device program in a nebulizer this program could open a drug container and/or aerosol valve(s) for nebulizer timing, gas modulation, and the like.

BRIEF SUMMARY OF THE INVENTION

The methods and apparatus in this present invention is provided to overcome one or more disadvantages of the prior art. In one embodiment, the invention directly controls a standard MDI valve of the type that is commonly used in FDA approved metered dose inhalers. The force and displacement to actuate this valve is provided by an electromechanical device that controls the timing and duration of the valve opening from the processor output using program, data inputs including possible sensors inputs. In this embodiment an electromechanical actuator can provide the program specified dose more accurately than the prior art.

In another embodiment, the invention directly controls a standard MDI valve of the type that is commonly used in FDA approved metered dose inhalers where the force and displacement to actuate this mechanical valve is provided by the user directly compressing a latching mechanism or using a lever to depress canister or set up valve for actuation. Then the program controlled actuator only triggers the valve opening with program controlled timing and duration using data from air flow breath activation and/or patient switch input.

In another embodiment, the invention directly controls a standard MDI valve of the type that is commonly used in FDA approved metered dose inhalers where the force and displacement to actuate this mechanical valve is provided by the propellant gas pressure from the previous valve actuation or other stored energy.

In another embodiment, the invention directly controls an electromechanical MDI valve similar to the types shown in U.S. Pat. No. 9,010,329 B2 instead of a standard mechanical MDI valve. This embodiment also includes additional sensors inputs and possible breath activation with program control which provides improvements over the prior art. A directly mounted valve may also eliminate the stagnant metering volume in some MDIs that need extra shaking and possible priming dose.

In additional embodiments, all the pressurized metered dose inhalers listed above a micro-heater is placed in a high flow region of the propellant/aerosol drug formulation to focus most of the heating on the discharged aerosol.

In this invention the program controlled micro-heater can have different power outputs for enhanced initial aerosol formation, increased propellant evaporation and increased solvent evaporation if ethanol or other solvent is added to the formulation. This micro-heater can compensate for low inhaler temperature and other conditions or simply improve aerosol formation. This micro-heater allows rapid heating of the aerosol drug formulation to minimize drug decomposition and minimize drug formulation separation. This is distinctly different from the vaporizer inhaler devices commonly available as electronic cigarettes (e-cigarettes, vape, and the like) where stagnant liquid is heated repeatedly in the presents of oxygen causing the separation and decomposition of many inhaled compounds.

Other additional embodiments include program control of dry powder inhalers and nebulizers. In the case of a dry powder inhaler the inhaler device program could control a powder container opener and/or electromechanical powder dispersion device. An inhaler device program for a nebulizer could open a drug formulation container and/or control aerosol valve(s) for nebulizer.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a diagram depicting a standard metered dose inhaler (MDI) metering valve and can in the first embodiment where the valve is actuated entirely by the force and displacement of the electromechanical actuator. Where 1 is the display that can show doses used and/or remaining, display warnings such as over/under temperature, almost out of doses, leaking inhaler, with optional beeper warning with other display options. Where 2 is the data input/output using wire or wireless communications. Where 3 is the central processing unit for controlling the MDI, Where 4 is the user aerosol output trigger switch that can be combined with breath activation data for dose release. Where 5 is the electromechanical aerosol valve actuator controlled by the program/MDI controller. Where 6 are sensors that may include but are not limited to temperature, flow, pressure, vibration, acceleration, breath detection, breath activation and the like, where 7 is the metered aerosol or particulate matter output dose that is inhaled. Where 8 is the aerosol source container. Where 9 is the mechanical aerosol valve that is activated by 4. This valve may be a large metering valve to allow partial volume release for dose control window of operation. Where 10 is the aerosol drug formulation fluid with propellant, additives and drug or drugs. Where 11 holds aerosol can in place for electromechanical operation of mechanical valve. Where 12 is a possible heating coil for propellant and drug formulation heating to enhance aerosol formation. Where 13 is the air inlet inhaled with aerosol. Where 14 is the aerosol outlet orifice.

DETAILED DESCRIPTION OF THE INVENTION

This patent describes the use of inputs for electronic control of medical aerosol generators or inhaler devices to optimize dose, optimize dose timing, optimize aerosol/particle size, optimize inhaled drug efficacy, or a combination of two or more thereof. This can be applied to the pressurized metered dose inhaler (MDI) with many potential advantages. The MDI input sensors can include but are not limited to switch pressed by patient ready for dose, air flow sensor that can trigger breath activation through processor, temperature sensor that can measure current MDI temperature and record temperature history, and possible pressure sensor. Program outputs can include but are not limited to MDI, display data, recorded data, program data, valve control and or formulation fluid heating.

In one embodiment, the invention directly controls a standard MDI valve of the type that is commonly used in FDA approved metered dose inhalers. The force and displacement to actuate this valve is provided by an electromechanical device that controls the timing and duration of the valve opening. In this configuration a large volume metering valve or continuous output valve will be used so that the electromechanical actuator can provide the program specified dose without large pressure drop during the dose that can cause a change in the aerosol size. This configuration will include most of the potential advantages of a processor electronically controlled MDI described in this patent including but not limited to possible fluid heating to enhance aerosol size distribution. The trapped volume metering valve in this configuration may also allow the aerosol drug/propellant fluid micro-heater to create higher pressures than inside the MDI canister when it is placed between the valve and outlet orifice as seen in 14 of FIG. 1 for the drawing of this embodiment.

In another embodiment, the invention directly controls a standard MDI valve of the type that is commonly used in FDA approved metered dose inhalers where the force and displacement to actuate this mechanical valve is provided by the user directly compressing a latching mechanism or using a lever to depress canister or set up valve for actuation. Then the program controlled valve actuator only triggers the valve opening with program controlled timing and duration using data from air flow breath activation and/or patient switch input. This configuration will include most of the potential advantages of a processor electronically controlled MDI described in this patent but minimized the force and displacement energy required to operate the mechanical MDI valve because the patient will provide this energy input.

In another embodiment, the invention directly controls a standard MDI valve of the type that is commonly used in FDA approved metered dose inhalers where the force and displacement to actuate this mechanical valve is provided by the propellant gas pressure from the previous valve actuation or other energy source.

In another embodiment, the invention directly controls an electromechanical MDI valve similar to the types shown in U.S. Pat. No. 9,010,329 B2 filed Feb. 10, 2010 instead of a standard mechanical MDI valve. This embodiment also includes sensors inputs and processor to control this valve so that this configuration will include the advantages of a processor controlled MDI described in this present invention. This valve directly mounted on the aerosol canister will have the advantage of no significant pressure drop from the limited small volume of the standard MDI valve. A directly mounted valve also has the potential advantage of low operating energy and more precise timing. This valve could also eliminate the stagnant metering volume in some MDIs that need extra shaking and possible priming dose. This direct canister mounted electromechanical MDI valve may integrate better with the drug formulation micro-heater discharged from the valve as an inhalable aerosol. Furthermore, the aerosol canister mounted electromechanical valve allows placement of the heater before or after the valve. When the micro-heater is used a preferred embodiment this places the micro-heater in a propellant/aerosol drug formulation high flow region where most of this heated aerosol formulation will be discharged during the valve activation for inhaled dose. This allows rapid heating of the aerosol drug formulation to minimize drug decomposition and minimize drug formulation separation. This is distinctly different from the vaporizer inhaler commonly available as electronic cigarette type devices where stagnant liquid is heated repeatedly in the presents of oxygen causing the separation and decomposition of many inhaled compounds. In this invention the electronically controlled micro-heater can have different power outputs for enhanced initial aerosol formation, increased propellant evaporation and increased solvent evaporation if ethanol or other solvent is added to the formulation. This directly mounted electromechanical valve also allows placement of a pressure sensor to monitor propellant/formulation pressure which is not currently available in FDA approved mechanical MDI metering valves.

List of potential advantages for processor/program controlled MDI valve or valve actuator.

-   -   1. Program controlled electromechanical MDI valve with program         variable open duration, dose release timing, and/or variable         flow can provide better dosing by compensating for current MDI         temperature, storage temperature, storage time/condition, number         of doses used, pressure, flow measurement and patient data.     -   2. Valve opening duration, flow rate control, and other outputs         for a MDI electromechanical valve or valve actuator can provide         a dose programmed specifically for the patient instead of only         fixed dose geometries offered by standard MDI with no         compensation for operating conditions.     -   3. Program for multifunction display can show doses used, doses         remaining, time to next dose, dose ready (“dose ready anytime         today”) (with optional beep or blink), days, weeks, months, left         for remaining doses, time left to expiration date, inhaler too         hot display (with optional beep or blink), battery low indicator         (with optional beep or blink), change aerosol canister.     -   4. The display program can show mass of aerosol drug dose in         each dose output for easy reading by patient, doctor, guardian         or pharmacist.     -   5. The electronic valve actuator with variable opening time and         possible variable flow with directly mounted electromechanical         valve can maintain more constant dose using programmed digital         temperature compensation which allows MDI use at high and low         temperature with the same dose even in hot or cold weather.     -   6. Processor/program controlled MDI could also use an aerosol         drug formulation/propellant fluid micro-heater in the valve         actuator or part of the valve assembly to compensate for         temperature to maintain aerosol size distribution especially in         cold weather.     -   7. The MDI electronic valve actuator can also control a heated         fluid (micro-heater) space after the valve and before the         orifice for improved aerosol size distribution with faster         propellant evaporation from smaller initial aerosols.     -   8. The MDI directly mounted electromechanical valve         configuration allows micro-heater before or after valve and         possible addition of can pressure sensor.     -   9. The MDI electronic valve with the addition of a pressure         sensor can also compensate for pressure drop with variable         opening time or duration as the MDI becomes empty.     -   10. The program in this MDI invention can detect mass flow         changes during use from leaking MDI or blocked orifice with flow         detection from micro-heater resistance (hot wire flow meter) or         other fluid mass flow sensors to signal MDI problem.     -   11. Program can also warn of leaks using time, pressure, flow         and usage data.     -   12. Program could prevent small orifice blockage with flow         detection and/or short time extra valve opening to clear         blockage.     -   13. The variable valve timing, duration, and opening, combined         with micro-heater time/power may overcome nearly all the         limitations of the standard mechanical MDI.     -   14. Processor/program controlled valve actuator and fluid         micro-heater could replace many metering volumes, jet/orifice         sizes and other geometric variables in mechanical only MDIs.     -   15. This invention electronically controls valve or valve         actuator providing an additional form of data to processor to         compensate for remaining drug formulation.     -   16. The electronic dose counter is triggered by program         controlled aerosol valve operation without over or under count         errors like add-on counter for mechanical MDIs. This provides         accurate dose counter for patient, guardian, pharmacy, etc.     -   17. Programmed dose reminder (blink, beep, or dose available now         display) could help many patients to remember to take inhaled         dose on time.     -   18. The time to next dose in the display program will help         patient planning the day.     -   19. The inhaler can beep or blink when it is close to the last         dose or past the last dose.     -   20. Doses and time remaining display will help patient plan time         for refill purchase.     -   21. Breath/dose counter can indicate and track multiple breath         doses for high dose drugs.     -   22. A program that includes actual inhaled dose time recorder         can help determine patient medication schedule compliance for         doctor review.     -   23. A programmable MDI could use cell phone, WiFi or other         communication for readable dose status or MDI compliance or MDI         history and current condition.     -   24. This MDI invention has the easy option to be programmed at         the pharmacy with patient specific dose instead of only fixed         doses offered by standard MDIs. Wire or wireless communications         can also be used to program patient information for best breath         activation and other patient specific operation.     -   25. Display on the MDI can show doses remaining, time to next         dose, dose ready, time left for remaining doses, time left to         expiration date, inhaler too hot, battery low indicator, remind         user to shake inhaler before use (with optional sound or blink).     -   26. This MDI invention could also be used to warn user if         re-priming is required if program detects storage time or         conditions that require re-priming MDI.     -   27. Program could respond to accelerometer or vibration detector         and/or position sensor to determine adequate shaking (ready         display after shaking) or remind user to shake inhaler before         inhaled dose. The program could also compensate for non-shaken         or inadequate shaking before use.     -   28. Over dose prevention can be programmed into electronic MDI         not allowing additional doses until next prescribed dose. This         could allow aerosol delivery of controlled substances and drugs         that need to be delivered close to dose limiting toxicity.     -   29. Programming for low battery warning could display safe         number of doses available before recharge.     -   30. Programming to store inhaler condition history can provide         additional data for optimized inhaled dose release.     -   31. Program for high temperature or low temperature alarm could         warn users before inhaler or drug formulations is permanently         damaged in incorrect storage conditions.     -   32. Storage conditions that can cause permanent damage (extreme         high/low temperature etc.) that can't be compensated by the MDI         program and could warn the user to acquire a new MDI.

This processor/program controlled MDI technology is vastly different than electronic dose recording and reporting MDIs which do not have temperature and other compensation for accurate dose delivery from an electronically controlled valve actuator or direct electromechanical valve and possible aerosol fluid micro-heater. The inhaled aerosol size and dose is accurately controlled in the MDI invention by valve opening, duration, timing, and possible discharge heating for best indication and best lung distribution of the drug. The electronic breath activation features listed below are also critical advancements over current mechanical breath activation systems. The processor/program controlled breath activation can be patient specific air flow and/or air volume triggered which is normally fixed in mechanical breath activation MDIs.

Advantages to Electronic Breath Activation

-   -   1. Programmable breath detection or breath activation flow and         volume can be adjusted for age and/or physical condition or         specific lung condition of the patient.     -   2. The possible combination of easy user activation switch         depression and breath flow activation could prevent accidental         aerosol dose discharges in backpack etc.     -   3. Accurate breath activation air flow can be programmed as         either/and/or logic combined with button activation (combination         button depression flow activation could prevent accidental dose         discharge).     -   4. Combination switch and breath detection is more likely to         record actual doses taken for better dose counting and recorded         inhalations.     -   5. The easy activation switch depression and programmable breath         flow activation will help elderly and young that are challenged         by the strong springs in the MDI valves.     -   6. The electronic breath activation eliminates coordination of         breathing with depression of standard MDI valve.     -   7. The programmable breath activation allows slow or fast         inhalation unlike some inhalers that may require fast inhalation         that is difficult or impossible for some patients.     -   8. The electronic breath activation prevents stuck activator         unlike mechanical breath activation on some MDI valves.     -   9. Breath flow detector can monitor and record patients         respiratory condition.     -   10. Breath detection and breath activation threshold can be         adjusted for age and/or physical condition or lung condition.     -   11. Electronic breath activation allows aerosol drug release at         the best inhalation flow and volume for the patient.     -   12. An important feature of this inhaler invention is the option         to program for early aerosol dose release timed for deep lung         delivery before most inhaled air instead of after most of the         inhaled air. This can improve peripheral lung deposition and         drug aerosol lung retention which could improve current aerosol         medicine and broaden the use of aerosol medicine to new drugs         and treatments.

Specific inhaler products from this invention do not need to include all the features listed above. The essential feature of this electronically controlled inhaler device is to overcome one or more disadvantages of the prior art. Important embodiments include more accurate dosing, accurate dose counting, and possible temperature compensation with temperature sensing. This invention provides an easy means to incorporate many features with the processor/program controlled inhaler device.

Example 1

This example illustrates certain embodiments of the invention using the micro-heater 12 shown in FIG. 1. In this example a pressurized excipient mixture of ethanol and the drug clofazimine was forced through a tubular micro-heater heated to a power level that completely evaporated the volatile components of the aerosol excipient mixture close to the aerosol discharge region of the aerosol outlet. This demonstrated that the micro-heater embodiment of this invention can form drug dry powders that can be directly inhaled with the advantages of this dry powder formation method. This method is not limited to dry powder inhalation of dry powder formation given that lower power to the micro-heater can form different aerosol size distributions to optimize deposition of inhaled aerosols in the lungs. This example also illustrates the advantage to oxygen free, single pass, rapid heating of the biologically active material minimizing drug decomposition of the prior art of the common e-cigarette type of vaporizer. 

1. a pressurized metered dose inhaler controller for controlled inhaled drug delivery of biologically active material(s), comprising: a. a digital processor that can control aerosol and/or drug particulate generating device for accurate dose control b. a memory that can store data for metered dose inhaler functions that include but are not limited to aerosol generator operations, dose prescribed, data to compensate for variable operating conditions, data for display, or a combination of two or more thereof c. a program that controls inhaled drug dose output using possible sensor condition data (such as temperature), user data, pharmacist input data, doctor input data, manufacturer input data, time data, count for doses used, count for doses remaining, other inhaler operating data or a combination of two or more thereof.
 2. A metered dose inhaler device according to claim 1, wherein a pressurized fluid or propellant type metered dose inhaler has an electromechanical valve or valve actuator that is controlled for best dose using program and controller to compensate for temperature of inhaler and/or environment.
 3. An inhaler device according to claim 1, wherein inhaled aerosol or particulate matter size is controlled for best indication and/or best lung distribution of the drug.
 4. A pressurized metered dose inhaler device according to claim 1, wherein electronic dose counter is triggered by program controlled aerosol valve operation and where it is not an add on switch to a mechanical MDI.
 5. The metered dose inhaler device according to claim 1, wherein a propellant MDI has a programmed dose that is primarily controlled by metered dose inhaler condition sensors and/or environmental condition sensors, stored data, and user dose trigger.
 6. A pressurized metered dose inhaler device according to claim 1, wherein the program controlled aerosol valve operation is an actuator add on to a standard mechanical MDI where the electromechanical actuator directly actuates a standard mechanical MDI valve without patient force/displacement effort to set up mechanical valve which only requires patient depression of a dose switch that can be combined with breath activation data to release and inhale dose at the best time.
 7. The metered dose inhaler device according to claim 1, wherein the program controlled aerosol valve operation is a new actuator add on to a standard mechanical MDI where the electromechanical actuator directly actuates standard mechanical MDI valve with patient force/displacement effort to set up mechanical valve where the valve is triggered with patient depression of a dose switch and/or breath activation data to release the dose for the best time of inhalation.
 8. The metered dose inhaler device according to claim 1, wherein the program controlled aerosol valve operation is a new actuator add on to a standard mechanical MDI valve. In this embodiment, the electromechanical actuator directly actuates standard mechanical MDI valve with MDI gas force and displacement.
 9. The metered dose inhaler device according to claim 1, wherein the program controlled device has an additional drug formulation heater and/or propellant mixture fluid heater to improve inhaled aerosols generated by the inhaler device.
 10. The metered dose inhaler device according to claim 1, wherein the program controlled device has additional fluid heating for solvent and/or propellant evaporation, possible viscosity reduction, better aerosol formation, with possibly less inhaler temperature dependent aerosol formation and temperature compensation.
 11. The metered dose inhaler device according to claim 9, wherein the fluid heater is before or after valve or before or after expansion orifice.
 12. The metered dose inhaler device according to claim 9, wherein the fluid heater is of any shape including but not limited to tubular, flat, coil and other shapes.
 13. The drug inhaler device according to claim 9 where drugs that are known to be active after evaporation or heating such as cannabinoid compounds, nicotine, and thermally stable biologically active materials are used with this device.
 14. A program for aerosol or dry powder delivery of biologically active materials for inhalation administration comprising: device where the program improves the treatment with better operation control and/or data usage comprising: a. an operating system program or inhaler device control program b. a program with one or more data inputs for dose operation, device variables, and customized device operation c. data output to control one or more electronic components operable to perform one or more functions of the inhaler device.
 15. The inhaler device program according to claim 14, wherein the dose of biologically active materials are controlled for safety to prevent overdose, underdose, or possible incorrect user dose.
 16. The inhaler device program according to claim 14, wherein stored data and/or collected data are used to improve the performance and/or efficacy of the inhaler device.
 17. The inhaler device program according to claim 14, wherein the program controls a pressurized fluid or propellant type metered dose inhaler where the inhaler device contains ethanol, water, carbon dioxide, difluoromethane, 1,1,1,2-tetrafluoroethane, or 1,1,1,2,3,3,3-heptafluoropropane, or a mixture of two or more thereof.
 18. The inhaler device program according to claim 14, wherein the program displays data for inhaler doses used, doses remaining, expiration date or time to expiration date, programmed dose for delivery, warnings like too hot, too cold, needs shaking, needs wasted priming dose, almost out of doses, inhaler battery low, inhaler needs to be replaced, or a combination of two or more thereof.
 19. The inhaler device program according to claim 14, wherein the program can use one or more data inputs from inhaler device user, device condition sensors and/or environmental condition sensors, to control dosing through processor to compensate for conditions and/or optimize dose.
 20. A Dry powder inhaler or nebulizer with dose timing and control with program control where the program controls inhaled drug dose output using one or more data inputs from sensor condition data, user data, pharmacist input data, health care provider input data, manufacturer input data, time data, inhaler condition sensor data and/or environmental condition sensor data or other data, to control dose through processor to optimize dose. 